Jacketing of structural batteries

Abstract

A battery with a layers including a first layer which is electrically conductive, a second layer consisting essentially of carbon-fiber-reinforced plastic, a third layer of glass-fiber-reinforced plastic, a fourth layer of carbon-fiber-reinforced plastic and LiFePO4, where the ratio by weight of LiFePO4 to carbon fiber is from 2:1 to 2.5:1, and a fifth layer which is electrically conductive, wherein the battery has substantially been jacketed by a layer made of glass-fiber-filled polyester.

The invention claimed is: 
     
       1. A battery with a plurality of layers comprising:
 a first layer, which comprises an electrically conductive material; 
 a second layer arranged on the first layer and consisting essentially of carbon-fiber-reinforced plastic; 
 a third layer arranged on the second layer, such that the second layer is positioned between the first layer and the third layer, and comprising glass-fiber-reinforced plastic; 
 a fourth layer arranged on the third layer, such that the third layer is positioned between the second layer and the fourth layer, and comprising carbon-fiber-reinforced plastic and LiFePO 4 , where a ratio by weight of LiFePO 4  to carbon fiber is from 2:1 to 2.5:1, 
 a fifth layer, which is arranged on the fourth layer and comprises an electrically conductive material; and 
 a jacketing layer made of glass-fiber-filled polyester that jackets the battery. 
 
     
     
       2. The battery according to  claim 1 , wherein the electrically conductive material of the first and/or of the fifth layer is metal or graphene. 
     
     
       3. The battery according to  claim 1 , wherein the jacketing layer made of glass-fiber-filled polyester is substantially coated with metal and/or ceramic on a side facing away from the battery. 
     
     
       4. The battery according to  claim 1 , wherein the jacketing layer made of glass-fiber-filled polyester comprises woven glass-fiber fabric. 
     
     
       5. The battery according to  claim 1 , wherein the jacketing layer made of glass-fiber-filled polyester is coated with SiO 2  on a side facing away from the battery. 
     
     
       6. The battery according to  claim 1 , wherein an arrangement of edges of the first to fifth layer is stepped. 
     
     
       7. A process for producing a battery, comprising:
 providing a battery with a plurality of layers comprising: 
 a first layer which comprises an electrically conductive material; 
 a second layer arranged on the first layer and consisting essentially of carbon-fiber-reinforced plastic; 
 a third layer arranged on the second layer, such that the second layer is positioned between the first layer and the third layer, and comprising glass-fiber-reinforced plastic; 
 a fourth layer arranged on the third layer, such that the third layer is positioned between the second layer and the fourth layer, and comprising carbon-fiber-reinforced plastic and LiFePO 4 , where a ratio by weight of LiFePO 4 , to carbon fiber is from 2:1 to 2.5:1; and 
 a fifth layer which is arranged on the fourth layer, and comprises an electrically conductive material; and 
 forming a layer made of glass-fiber-filled polyester that jackets the battery; 
 wherein the first layer, the fifth layer, and the jacketing layer are positioned via AFP or ATL and are consolidated via laser or ultrasound welding. 
 
     
     
       8. A component comprising:
 a plurality of batteries that each have a plurality of layers and are provided over an area of the component, bonded to one another at their edges, and each comprise:
 a first layer, which comprises an electrically conductive material; 
 a second layer arranged on the first layer and consisting essentially of carbon-fiber-reinforced plastic; 
 a third layer arranged on the second layer, such that the second layer is positioned between the first layer and the third layer, and comprising glass-fiber-reinforced plastic; 
 a fourth layer arranged on the third layer, such that the third layer is positioned between the second layer and the fourth layer, and comprising carbon-fiber-reinforced plastic and LiFePO 4 , where a ratio by weight of LiFePO 4  to carbon fiber is from 2:1 to 2.5:1; 
 a fifth layer, which is arranged on the fourth layer and comprises an electrically conductive material; and 
 
 a jacketing layer made of glass-fiber-filled polyester that jackets the battery. 
 
     
     
       9. The component according to  claim 8 , where the bonded batteries are heat press bonded.